US10222048B2 - Light emitting device and method for manufacturing a light emitting device - Google Patents

Light emitting device and method for manufacturing a light emitting device Download PDF

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Publication number
US10222048B2
US10222048B2 US14/383,595 US201314383595A US10222048B2 US 10222048 B2 US10222048 B2 US 10222048B2 US 201314383595 A US201314383595 A US 201314383595A US 10222048 B2 US10222048 B2 US 10222048B2
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Prior art keywords
heat sink
sink element
circuit layer
led package
substrate
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Expired - Fee Related, expires
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US14/383,595
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English (en)
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US20150109793A1 (en
Inventor
Antonius Petrus Marinus Dingemans
Wilhelmus Gerardus Maria Peels
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Signify Holding BV
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Philips Lighting Holding BV
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Assigned to KONINKLIJKE PHILIPS ELECTRONICS N V reassignment KONINKLIJKE PHILIPS ELECTRONICS N V ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PEELS, WILHELMUS GERARDUS MARIA, DINGEMANS, ANTONIUS PETRUS MARINUS
Publication of US20150109793A1 publication Critical patent/US20150109793A1/en
Assigned to PHILIPS LIGHTING HOLDING B.V. reassignment PHILIPS LIGHTING HOLDING B.V. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KONINKLIJKE PHILIPS N.V.
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00—Reflectors for light sources
    • F21V7/22—Reflectors for light sources characterised by materials, surface treatments or coatings, e.g. dichroic reflectors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/60—Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V23/00—Arrangement of electric circuit elements in or on lighting devices
    • F21V23/04—Arrangement of electric circuit elements in or on lighting devices the elements being switches
    • F21V23/0442—Arrangement of electric circuit elements in or on lighting devices the elements being switches activated by means of a sensor, e.g. motion or photodetectors
    • F21V23/0457—Arrangement of electric circuit elements in or on lighting devices the elements being switches activated by means of a sensor, e.g. motion or photodetectors the sensor sensing the operating status of the lighting device, e.g. to detect failure of a light source or to provide feedback to the device
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/502—Cooling arrangements characterised by the adaptation for cooling of specific components
    • F21V29/505—Cooling arrangements characterised by the adaptation for cooling of specific components of reflectors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/04—Refractors for light sources of lens shape
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/10—Refractors for light sources comprising photoluminescent material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00—Reflectors for light sources
    • F21V7/04—Optical design
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/50—Wavelength conversion elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00—Reflectors for light sources
    • F21V7/0091—Reflectors for light sources using total internal reflection
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.

Definitions

  • the present invention relates generally to a light emitting device having a heat sink element surface mounted adjacent a LED package on the circuit layer of a substrate.
  • the invention relates also to a method for manufacturing such a light emitting device.
  • LED-modules are manufactured in different ways from the typical 5 mm through hole signaling components to Chip on Board. At this moment, for general lighting, surface mounted technology (SMT), is the dominant technology. SMT is automated and places components for an electrical product on a printed circuit board (PCB).
  • PCB printed circuit board
  • heat sinks of different kinds are used.
  • a known way is to use capped filled vias in the PCB to lead heat through the PCB to a heat conductor on the backside of the PCB.
  • the heat conductor is often part of a metal heat sink that is exposed to the ambient air.
  • vias for heat conduction is, however, both costly and sets demands on electronic insulation, limiting and complicating the design of the component and its PCB.
  • a light emitting device comprising a substrate having an electrically conducting circuit layer, a LED package surface mounted on the substrate and electrically connected to the circuit layer, and a heat sink element, surface mounted on the substrate separately from the LED package.
  • the heat sink element has a body of a heat conductive material surrounding the LED package, the body being in thermal contact with the circuit layer and being adapted to provide heat dissipation from the circuit layer to a surrounding environment.
  • the surface of the heat sink element facing the LED package is further adapted to act as a beam shaper for shaping light emitted from the LED package.
  • the heat sink body is in thermal contact with the circuit layer, the heat resistance from the LED package to the heat sink body via the circuit layer is minimized.
  • the heat sink element is surface mounted on the substrate (just like the LED package), it may further be arranged very close to, and preferably in direct contact with, the circuit layer. This further reduces the heat resistance from the LED package to the heat sink body.
  • a LED-package is in this context intended to a component which may be surface mounted on a substrate, and which includes at least one LED die.
  • the substrate is usually a PCB, but could be any other substrate having an electrically conducting circuit layer onto which LED package and other electrical components may be mounted.
  • the heat sink body made of a heat conductive material, directs heat to the thermal interface when the surrounding environment is cooler than the heat sink body.
  • the optical interface is arranged facing the LED package to direct light emitted from the LED package. The optical interface typically surrounds the LED package on the substrate.
  • the surface mounting of the heat sink element on the circuit layer can be done before or after soldering the LED package to the circuit layer, making the mounting of the beam shaping optics an integrated piece in the LED board manufacturing process.
  • optical and thermal functionalities can be added at the same time, in the same process as is used to mount the LED packages.
  • the heat sink elements are picked, placed and soldered at the same time, using the same processes as for the LED packages. This will save costs enabling possibilities to make cheap LED products with desired emission quality.
  • cost can be kept low with reasonable quality.
  • quality will be very good, due to the good heat dissipation that comes from the direct heat transfer.
  • the beam shaping optics will further be self aligned with the LED package, as the solder strives to reach its lowest energy state.
  • the heat sink element is preferably electrically connected to the circuit layer. This means that the heat sink element will form part of the electrical circuit, and can include components that can be powered and controlled through the circuit.
  • the heat sink element may for example include light sensors (Lm, CTT a.o.) and actuators (shutters) connected to the beam shaping optics. By sensing the light directly in the beam, this may provide very advantageous functionality.
  • the heat sink body may be made of a metal, e.g. aluminum, copper, preferably a metal having a high heat conductivity.
  • the heat sink body may e.g. be made of a metal sheet or foil, having a reflective surface at a side facing the LED package. This solution is simple, but fairly efficient, providing a cost effective solution.
  • the heat sink body may also be made of a, at least partly, transparent material. It is not always that it is desired to shape the emission from the LED-package. If the LED should only give diffuse light, the optical heat sink body may be made of a transparent material having incorporated highly reflective particles to increase the scattering coefficient of the material still keeping absorption at low levels.
  • the surface facing the LED package may be transparent, highly reflective, Lambertian reflective or specular. The choice depends on the optical beam properties wanted, price of the product, etc.
  • the surface facing the LED package may further be provided with phosphorescent material adapted to convert the color of the LED radiation.
  • phosphorescent material adapted to convert the color of the LED radiation.
  • most high power white LEDs emit light in a narrow blue wavelength region and need to be color converted to be perceived as white by the human eye. This is normally done using phosphor conversion, where a phosphor powder, e.g. YAG:Ce, is excited by the blue LED emission, converting a large portion of the blue emission to a broadband emission in the red region.
  • a phosphor powder e.g. YAG:Ce
  • Adding the phosphor to the optical interface of the optical heat sink body can be done cheaper and with less precision since it can be applied before mounting the optical heat sink. Adding phosphor directly to the LED die is a delicate and thereby expensive operation.
  • the heat sink element may comprise two electrically and thermally separated parts, each thermally connected to the circuit layer.
  • the two parts may be connected to different terminals of the LED package mounted on the circuit layer, in which case the two parts must be electrically insulated so as to avoid a short circuit.
  • the parts may be separated either by air or a non-conducting material as a ceramic or rubber material.
  • the separating material is preferably pre-mounted to avoid having to place two components onto the substrate.
  • the heat sink element further comprises a lens supported by and in thermal connection with the body, which lens is positioned in front of an emission surface of the LED package.
  • precision beam shaping may be accomplished by surface mounted technology, while keeping the optical lens cooled by the heat sink.
  • the lens could be a molded lens or basically any lens pre-mounted to the heat sink element. Precession mounting of the lens is thus accomplished automatically by the standard SMT. Another advantage is that the lens may be placed very close to the LED-die.
  • the invention further relates to a method of assembling a light emitting device, comprising providing a surface of a substrate with an electrically conducting circuit layer, surface mounting a LED-package on the substrate, in electrical connection with the circuit layer, and surface mounting a separate heat sink element on the substrate, adjacent to the LED package, such that the heat sink element is brought into thermal connection with the circuit layer, so as to provide heat dissipation from the circuit layer to a surrounding environment.
  • the mounting steps may be performed using standard SMT processes, with all the benefits following that, as discussed above.
  • FIG. 1 is a cross sectional view of an embodiment of a light emitting device according to a first embodiment of the present invention.
  • FIG. 2 a is a cross sectional view of an embodiment where the heat sink element is a metal sheet shaped in a parabolic shape.
  • FIG. 2 b is a cross sectional view of an embodiment where the heat sink element comprises a lens that is positioned just above the LED.
  • FIG. 2 c is a cross sectional view of an embodiment where the heat sink element is a white cup.
  • FIG. 3 a is a cross sectional view of an embodiment where the heat sink element with lenses is placed around multiple LEDs.
  • FIG. 3 b is a cross sectional view of an embodiment where the heat sink element is a white cup placed around multiple LEDs.
  • FIG. 4 a is a topographic view of the PCB layout of two embodiments of the present invention.
  • FIG. 4 b is a topographic view of the copper layer layout of the two embodiments in FIG. 4 a.
  • FIG. 4 c is a topographic view of the LED footprint of the two embodiments in FIG. 4 a.
  • FIG. 4 d is a topographic view of the optical heat sink footprints of the two embodiments in FIG. 4 a.
  • FIG. 4 e is a perspective view of the two embodiments of the PCB layout with LEDs, basically a combination of FIG. 4 a and FIG. 4 c.
  • FIG. 4 f is a perspective view of the two embodiments of FIG. 4 e with metal parts of the heat sink element added.
  • FIG. 4 g is a perspective view of the two embodiments of FIG. 4 f with material covering the metal parts added to provide embodiments with white cup optical interfaces.
  • FIGS. 4 h and 4 i show a folded and a non-folded metal sheet used as heat sink element.
  • FIG. 1 shows a cross sectional view of an embodiment of a light emitting device according to the invention, including a substrate 6 , here a PCB, onto which a LED package 7 and a heat sink element 1 have been mounted using surface mounting technology (SMT).
  • the heat sink element 1 also referred to as an “optical heat sink”, comprises a heat sink body 2 of a heat conductive material, and an optical interface 3 , arranged on the surface of the body 2 .
  • the optical interface forms part of a beam shaping optics, and may be made of a material providing desired optical properties, and can be transparent, highly reflective lambertian/white or specular.
  • the heat sink body 2 further has a thermal interface 4 exposed to the surrounding environment, usually air.
  • the optical heat sink 1 further has a solder connection 5 .
  • the optical heat sink 1 is intended to be connected on the copper wiring 8 of the PCB 6 substrate using the solder connection 5 .
  • the optical heat sink is arranged to surround the LED-package 7 so that light from the LED package will be incident on the optical interface 3 , and so that heat from the LED-package 7 will dissipate via the copper layer 8 and the heat sink body 2 out to the surrounding.
  • the heat sink element may be not only thermally, but also electrically, connected to the circuit layer. For example, it may be electrically connected to one or both of the terminals for the LED-package, or be connected to a so called “heat slug” of the LED package.
  • An electrical terminal that the optical heat sink is connected to is preferably made large enough to fit the footprint of a connection part of the heat sink body (the part in contact with the substrate). Such a LED package terminal may therefore be much larger in surface area than a regular LED package terminal.
  • the optical interface 2 of the heat sink element may have a parabolic shape, like the reflector in a car headlamp. Since the LED package 7 is usually rectangular, it may, however, be more practical to make also the optical interface, and thereby the entire heat sink element, rectangular. For simplicity, and since a collimated beam shape is not always desired, the shape of the optical interface 2 may be made as a flat surface, angled away from the LED, taking the shape of a cup that is not parabolic, but still has a smaller area at the base/PCB than at the top (away from the PCB).
  • FIG. 2 a shows a cross sectional view of an embodiment where the optical heat sink 1 is made of a metal sheet 21 shaped in a parabolic shape.
  • the metal sheet will by itself provide the optical heat sink body 2 , 21 , the optical interface 3 , 21 , the thermal interface 4 , 21 and solder connection 5 , 21 .
  • the embodiment using metal sheet 21 provides a cheap but in many cases satisfactory solution.
  • the metal sheet may have different shapes. In FIG. 2 , the sheet has a parabolic shape, creating a fairly parallel beam shape from the LED, but the shape could also be straight as a cup, or any other wanted shape.
  • the metal sheet may be used as a foundation for any coating that could be desired, e.g., as a foundation in the embodiment of FIG. 2 c.
  • the heat sink element is electrically connected between two connection points on the circuit layer, it will form part of the electrical circuit, and may thus include electrical components that can be powered and controlled through the circuit layer.
  • the electrical components may be for example light sensors, actuators, etc. This is illustrated schematically in FIG. 2 b by component 29 .
  • a light sensor may be, e.g., a light meter (Lm), a CTT etc, and can be arranged to measure properties such as intensity or color of the emitted light.
  • the actuator could be, e.g., a shutter affecting the reflector, collimator, or lens according to the embodiments above.
  • FIG. 2 b shows a cross sectional view of an embodiment where the optical heat sink has a lens 9 that is positioned just above the LED.
  • the lens 9 is held by a folded metal sheet 21 ′ that serves as thermal and optionally also as reflective optical interface.
  • the metal sheet 21 ′ holds the lens 9 in a holding device 10 , attached to hold the lens 9 .
  • the optical design for LED lighting products typically has to manage two functions, lowering source brightness and beam shaping.
  • the described embodiment of the present invention involves near die optics that are especially useful for the latter function. Solving the beam shaping problem on a board level limits the optical design on the luminaire level only to lowering the source brightness.
  • the lens may, in accordance with the invention, have its lower surface 23 covered by a phosphor coating to provide wavelength conversion of the LED emission.
  • the phosphor coating will then fully replace the functionality of having phosphor coated directly on the LED-die.
  • the remaining surfaces of the lens 9 could also be covered by phosphor coating to provide a more complete wavelength conversion, at the expense of the lens effect. The latter could, however still be interesting if the lens is a cheap molded lens, to reduce the number of possible components in a production facility.
  • the lens 9 may be a clear lens. However, if diffuse light is desired the lens may be replaced by any other a similar sized optical component, held by the heat sink element.
  • the lens can be made of a transparent material with phosphor particles molded into it. The optics of the heat sink element will then serve to reflect also phosphorescence that is emitted in the wrong direction from the phosphor particles.
  • FIG. 2 c shows a cross sectional view of an embodiment where the optical heat sink is a white cup 22 .
  • the white surface diffuses the light from the LED and gives it less direction. The surface serves to reduce the brightness perceived by a person looking at the LED-device.
  • FIG. 3 a shows a cross sectional view of an embodiment where an optical heat sink having attached clear lenses is placed around multiple LEDs.
  • One clear lens 9 per LED 7 is held by a folded metal sheet 31 and the lens holding device 10 ′.
  • FIG. 3 b shows a cross sectional view of an embodiment where the optical heat sink is a white cup 32 placed around multiple LEDs.
  • a metal sheet 31 ′ is incorporated into the white cup to lead heat from the LED package 7 via the circuit layer.
  • the white material could be plastic with strongly diffusing properties as in FIG. 2 c , but it could also be a phosphor containing material having incorporated phosphor particles for light wavelength conversion.
  • FIG. 4 a - i shows parts and layers of two possible embodiments of the present invention.
  • FIG. 4 a the PCB layout of two embodiments 41 , 42 are shown.
  • the embodiment 41 to the left has one LED-package, while the embodiment 42 to the right has eight LED-packages.
  • FIG. 4 b shows the copper layer layout
  • FIG. 4 c shows the LED footprint
  • FIG. 4 d shows the optical heat sink footprints of the two embodiments.
  • FIG. 4 e shows a perspective view of the two embodiments of the PCB layout with LEDs, basically a combination of FIG. 4 a and FIG. 4 c
  • FIG. 4 f shows the two embodiments of FIG. 4 e with the metal parts of the optical heat sink added.
  • the metal parts in this embodiment are folded metal sheet as shown in FIG. 4 h and FIG. 4 i .
  • the two embodiments of FIG. 4 f are supplied with material covering the metal parts to provide embodiments with white cup optical interfaces.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Manufacturing & Machinery (AREA)
  • Computer Hardware Design (AREA)
  • Power Engineering (AREA)
  • Led Device Packages (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)
US14/383,595 2012-03-08 2013-03-06 Light emitting device and method for manufacturing a light emitting device Expired - Fee Related US10222048B2 (en)

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US201261608178P 2012-03-08 2012-03-08
PCT/IB2013/051776 WO2013132446A1 (en) 2012-03-08 2013-03-06 Light emitting device and method for manufacturing a light emitting device
US14/383,595 US10222048B2 (en) 2012-03-08 2013-03-06 Light emitting device and method for manufacturing a light emitting device

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EP (1) EP2823226B1 (ja)
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US10119680B2 (en) * 2015-03-27 2018-11-06 Gary Wayne Engelhardt Retrofit light emitting diode fixture for a back box
US10982834B2 (en) * 2017-11-17 2021-04-20 Smart Light Source Co., LLC Thermal control of locomotive headlight

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